Manufacturing Productivity Use Cases

Improve With XL

The XL Productivity Appliance™ is an extremely flexible and powerful tool for improving manufacturing productivity. Our goal with XL is simple – make it incredibly easy for you to achieve unprecedented improvements in manufacturing productivity.

To give you a better sense of how XL can help, we have put together a collection of popular manufacturing improvement use cases that are enhanced by XL.

The XL Productivity Appliance surrounded by reports.

Use Cases

Create a Digital Twin

Simulate Your Process

The deeper your understanding of your process, the more effectively you can target your improvement efforts. What better way to understand your process than to create a digital model of it?

We have simplified this idea into an actionable first step toward simulating and improving your process.

Learn More About Creating a Digital Twin

What a Digital Twin Is

Where to Begin Implementation

Benefits of A Digital Twin

Image of eight andons, each with real-time information about a production line.

Improve Productivity

The Core Imperative

It can be difficult to know where to start when embarking on a broad program to improve manufacturing productivity. There's a lot of well-written and insightful theory, but much less in the way of practical tips and insights.

So while you are evaluating large-scale initiatives like Lean Manufacturing, Theory of Constraints, and Six Sigma, we have hand-picked three of our favorite strategies for delivering quick wins.

Learn More About Improving Productivity

Accurately Identify Your Losses

Attack Your Top Losses

Apply Short Interval Control

Top losses report showing OEE factor KPIs and your top 5 losses ranked by lost time.

Increase Capacity

Unlock Your Hidden Factory

Have you ever heard of the “hidden factory”? It's a really useful concept, based on the fact that most equipment is not used anywhere near its true capacity. In fact, the difference between typical manufacturing (OEE score of 60%) and world-class manufacturing (OEE score of 85%) represents a 41.6% increase in capacity.

So before you purchase new equipment to increase capacity, make sure you know how much untapped potential there is in your factory.

Learn More About Increasing Capacity

Measure Overall Equipment Effectiveness (OEE)

Measure Total Effective Equipment Performance (TEEP)

Table with capacity losses, the six big losses, and perfect production explained.

Reduce Changeover Times

More Run, Less Inventory

Changeovers are periods of time where equipment is unavailable due to tooling changes, material changes, or any other changes to production that must be performed while equipment is stopped. By applying best practices to changeovers, their duration can often be reduced to less than 10 minutes.

Shorter changeovers mean more time for running production, smaller batch sizes, and less inventory.

Learn More About Reducing Changeover Times

Implement Single-Minute Exchange of Die (SMED)

Make Changeover Time Visual

Provide Advance Notification of Changeovers

Report showing KPIs for changeover time, changeover events, and planned stops, with a pareto chart showing changeover time by part underneath.

Reduce Cycle Times

Make Every Cycle Count

Cycle time loss occurs whenever equipment runs slower than its maximum theoretical speed (the Ideal Cycle Time). It's an aspect of production that benefits greatly from automated measurement as cycle losses are extremely difficult to capture manually. As a result, many manufacturers find that cycle time losses are hidden – they are not tracked and not acted upon.

Learn More About Reducing Cycle Times

Validate Your Cycle Time Standards

Understand Your Cycle Time Losses

Attack Cycle Time Loss on the Factory Floor

Bar chart showing slow cycles loss by part, with cycle loss much higher than small stop loss for every part.

Reduce Down Time

Attack the Largest Source of Lost Time

Down time typically gets a high level of focus in manufacturing. Equipment failures and breakdowns are highly visible, and for most manufacturers unplanned stops are the single largest source of lost production time.

Reducing down time is often the fastest and most direct path to improved manufacturing productivity. Unfortunately, many companies don't realize that their down time information is both inaccurate and insufficient. Fortunately, this is an easy problem to fix.

Learn More About Reducing Down Time

Track Down Time Accurately

Categorize Down Time with Reasons

Expose Down Time in Real-Time

Attack the Largest Sources of Down Time

XL unit showing line down in front of a report showing KPIs for Down Time, Down Events, MTFB, and MTTR.

Reduce Manufacturing Costs

Spend Less, Make More

There are two particularly interesting perspectives on reducing manufacturing costs: spend less (manufacture the same number of parts in less time) OR make more (manufacture more parts in the same time).

Lean Manufacturing tends to focus on the former (by eliminating waste), while the Theory of Constraints tends to focus on the latter (by increasing throughput). Both offer proven techniques for reducing manufacturing costs.

Learn More About Reducing Manufacturing Costs

Attack Your Top Losses

Improve the Constraint

Win the Shift

Table showing that if you spend 10% less and make 10% more, you can increase profits by 62%.

Win the Shift

Plan, Adjust, Debrief

When your operators are equipped to hit a production target and “win the shift”, you’re guaranteed to win your week, month, and quarter.

Learn More About Winning the Shift

Plan to Win

Track Production in Real-Time

XL device showing an efficiency of 104%, indicating operators are winning their shift.
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